Roughing cutting insert

ABSTRACT

A cutting insert for use in a chipforming material removal operation that includes a cutting insert body, which has a seating surface, a flank face, and a corner cutting region at the intersection of a peripheral edge and the flank adjacent corresponding corners thereof. The cutting insert body contains a central aperture. The seating surface contains a coolant delivery trough, which has a radial orientation toward a corresponding corner cutting region. The coolant delivery trough has a radial outward end terminating at the peripheral edge and a radial inward end opening into the central aperture. There are a pair of lateral topographic regions wherein the one lateral topographic region is along one side of the coolant delivery trough and the other lateral topographic region is along other side of the coolant delivery trough.

CROSS-REFERENCE TO EARLIER PATENT APPLICATIONS

This patent applications is a divisional patent application to pendingU.S. patent application Ser. No. 12/878,460 filed Sep. 9, 2010 forCUTTING INSERTS by Chen et al., which is a continuation-in-part ofpending U.S. patent application Ser. No. 12/874,591 filed on Sep. 2,2010 by Shi Chen et al. for CUTTING INSERT ASSEMBLY AND COMPONENTSTHEREOF, which is a continuation-in-part of U.S. patent application Ser.No. 11/654,918 filed on Jan. 18, 2007 (now U.S. Pat. No. 7,883,299,issued Feb. 8, 2011) by Paul D. Prichard et al. for METALCUTTING SYSTEMFOR EFFECTIVE COOLANT DELIVERY.

Applicants hereby claim priority based upon said U.S. patent applicationSer. No. 12/878,460 filed Sep. 9, 2010 for CUTTING INSERTS by Chen etal. and hereby claim priority based upon said U.S. patent applicationSer. No. 12/874,591 filed on Sep. 2, 2010 by Chen et al. Further,applicants hereby incorporate herein in its entirety such U.S. patentapplication Ser. No. 12/878,460 filed Sep. 9, 2010 for CUTTING INSERTSby Chen et al. and hereby incorporate herein in its entirety such U.S.patent application Ser. No. 12/874,591 filed on Sep. 2, 2010.

BACKGROUND OF THE INVENTION

The subject invention pertains to a metal cutting system and, inparticular, to a metal cutting system adapted to facilitate enhanceddelivery of coolant adjacent the interface between the cutting insertand the workpiece (i.e., the insert-chip interface) to diminishexcessive heat at the insert-chip interface in the chipforming removalof material from a workpiece. The subject invention is directed furtherto components of such metal cutting systems. Such components include,for example, a locking pin, a clamp assembly, a holder, a shim andespecially the cutting insert.

Metal cutting tools for performing metal working operations generallycomprise a cutting insert having a surface terminating at a cutting edgeand a tool holder formed with a seat adapted to receive the insert. Thecutting insert engages a workpiece to remove material, and in theprocess forms chips of the material. Excessive heat at the insert-chipinterface can negatively impact upon (i.e., reduce or shorten) theuseful tool life of the cutting insert.

For example, a chip generated from the workpiece can sometimes stick(e.g., through welding) to the surface of the cutting insert. The buildup of chip material on the cutting insert in this fashion is anundesirable occurrence that can negatively impact upon the performanceof the cutting insert, and hence, the overall material removaloperation. A flow of coolant to the insert-chip interface will reducethe potential for such welding. It would therefore be desirable toreduce excessive heat at the insert-chip interface to eliminate orreduce build up of chip material.

As another example, in a chipforming material removal operation, therecan occur instances in which the chips do not exit the region of theinsert-chip interface when the chip sticks to the cutting insert. When achip does not exit the region of the insert-chip interface, there is thepotential that a chip can be re-cut. It is undesirable for the millinginsert to re-cut a chip already removed from the workpiece. A flow ofcoolant to the insert-chip interface will facilitate the evacuation ofchips from the insert-chip interface thereby minimizing the potentialthat a chip will be re-cut.

There is an appreciation that a shorter useful tool life increasesoperating costs and decreases overall production efficiency. Excessiveheat at the insert-chip interface contribute to the welding of chipmaterial and re-cutting of chips, both of which are detrimental toproduction efficiency. There are readily apparent advantages connectedwith decreasing the heat at the insert-chip interface wherein one way todecrease the temperature is to supply coolant to the insert-chipinterface.

Heretofore, systems operate to lower the cutting insert temperatureduring cutting. For example, some systems use external nozzles to directcoolant at the cutting edge of the insert. The coolant serves not onlyto lower the temperature of the insert but also to remove the chip fromthe cutting area. The nozzles are often a distance of one to twelveinches away from the cutting edge. This is too far of a distance foreffective cooling. The farther the coolant must travel, the more thecoolant will mix with air and the less likely it will be to contact thetool-chip interface.

U.S. Pat. No. 6,053,669 to Lagerberg for CHIP FORMING CUTTING INSERTWITH INTERNAL COOLING discusses the importance of reducing the heat atthe insert-chip interface. Lagerberg mentions that when the cuttinginsert is made from cemented carbide reaches a certain temperature, itsresistance to plastic deformation decreases. A decrease in plasticdeformation resistance increases the risk for breakage of the cuttinginsert. U.S. Pat. No. 5,775,854 to Wertheim for METAL CUTTING TOOLpoints out that a rise in the working temperature leads to a decrease inhardness of the cutting insert. The consequence is an increase in wearof the cutting insert.

Other patent documents disclose various ways to or systems to delivercoolant to the insert-chip interface. For example, U.S. Pat. No.7,625,157 to Prichard et al. for MILLING CUTTER AND MILLING INSERT WITHCOOLANT DELIVERY pertains to a cutting insert that includes a cuttingbody with a central coolant inlet. The cutting insert further includes apositionable diverter. The diverter has a coolant trough, which divertscoolant to a specific cutting location.

U.S. Pat. No. 6,045,300 to Antoun for TOOL HOLDER WITH INTEGRAL COOLANTPASSAGE AND REPLACEABLE NOZZLE discloses using high pressure and highvolume delivery of coolant to address heat at the insert-chip interface.U.S. Pat. No. 6,652,200 to Kraemer for a TOOL HOLDER WITH COOLANT SYSTEMdiscloses grooves between the cutting insert and a top plate. Coolantflows through the grooves to address the heat at the insert-chipinterface. U.S. Pat. No. 5,901,623 to Hong for CRYOGENIC MACHININGdiscloses a coolant delivery system for applying liquid nitrogen to theinsert-chip interface.

SUMMARY OF THE INVENTION

The inventor(s) have recognized the problems associated withconventional cooling apparatus and have developed an insert assemblythat works with a conventional coolant system to deliver coolant to acutting insert that addresses the problems of the prior art.

In one form thereof, the invention is a roughing cutting insert for usein a chipforming material removal operation. The cutting insertcomprises a cutting insert body that has a seating surface and a flankface and a corner cutting region at the intersection of a peripheraledge and the flank adjacent corresponding corners thereof. The cuttinginsert body contains a central aperture. The seating surface contains acoolant delivery trough that has a radial orientation toward acorresponding corner cutting region. The coolant delivery trough has aradial outward end terminating at the peripheral edge and a radialinward end opening into the central aperture. The cutting insert bodyhas a pair of lateral topographic regions wherein the one lateraltopographic region is along one side of the coolant delivery trough andthe other lateral topographic region is along other side of the coolantdelivery trough, and each one of the topographical regions comprises aperipheral notch.

In still another for thereof, the invention is a medium roughing cuttinginsert for use in a chipforming material removal operation. The cuttinginsert comprises a cutting insert body that has a seating surface and aflank face and a corner cutting region at the intersection of aperipheral edge and the flank adjacent corresponding corners thereof.The cutting insert body contains a central aperture. The seating surfacecontains a coolant delivery trough that has a radial orientation towarda corresponding corner cutting region. The coolant delivery trough has aradial outward end terminating at the peripheral edge and a radialinward end opening into the central aperture. The cutting insert bodyhas a pair of lateral topographic regions wherein the one lateraltopographic region is along one side of the coolant delivery trough andthe other lateral topographic region is along other side of the coolantdelivery trough. Each one of the topographical regions comprises alateral notch having a forward-facing beveled face and a beveled lateralface being generally parallel to the coolant delivery trough. Thebeveled lateral face decreases in area from an intersection with theforward-facing beveled face and a termination with the peripheral edge.

In still another form thereof, the invention is a finishing cuttinginsert for use in a chipforming material removal operation. The cuttinginsert comprises a cutting insert body that has a seating surface and aflank face and a corner cutting region at the intersection of aperipheral edge and the flank adjacent corresponding corners thereof.The cutting insert body contains a central aperture. The seating surfacecontains a coolant delivery trough that has a radial orientation towarda corresponding corner cutting region. The coolant delivery trough has aradial outward end terminating at the peripheral edge and a radialinward end opening into the central aperture. The cutting insert bodyhas a pair of lateral topographic regions wherein the one lateraltopographic region is along one side of the coolant delivery trough andthe other lateral topographic region is along other side of the coolantdelivery trough. Each one of the topographical regions comprises alateral notch having a forward-facing beveled face and a beveled lateralface being generally parallel to the coolant delivery trough, andwherein the beveled lateral face decreases in area from an intersectionwith the forward-facing beveled face and a termination with theperipheral edge. A plurality of projections are on the beveled lateralface.

A cutting insert for use in a chipforming material removal operation.The cutting insert comprises a cutting insert body that has a seatingsurface and a flank face and a corner cutting region at the intersectionof a peripheral edge and the flank adjacent corresponding cornersthereof. The cutting insert body contains a central aperture. Theseating surface contains a coolant delivery trough that has a radialorientation toward a corresponding corner cutting region. The coolantdelivery trough has a radial outward end terminating at the peripheraledge and a radial inward end opening into the central aperture. Thecutting insert body has a pair of lateral topographic regions whereinthe one lateral topographic region is along one side of the coolantdelivery trough and the other lateral topographic region is along otherside of the coolant delivery trough.

BRIEF DESCRIPTION OF THE DRAWINGS

The following is a brief description of the drawings that form a part ofthis patent application:

FIG. 1 is an exploded view of the invention with rake face cooling only;

FIG. 2 is an exploded view of the invention with rake and flank cooling;

FIG. 3 is a perspective view of the invention with rake face cooling andjets;

FIG. 4 is a perspective view of the preferred embodiment of theinvention with high volume flank cooling, rake face cooling and jets;

FIG. 5 is a cross section of a perspective view of the invention withrake and flank face cooling;

FIG. 6 is a cross section of a perspective view of the invention withrake and high volume flank face cooling;

FIG. 7 is a cross-sectional perspective of the invention engaging aworkpiece and forming a chip;

FIG. 8 is a cross section of a perspective view of the clamp and toppiece fixed together with a slotted spring pin;

FIG. 9 is a view of the insert side of the top piece with a centeringstud;

FIG. 10 is a perspective view of the centering stud;

FIG. 11 is an isometric view of another specific embodiment of thecutting assembly, which comprises a holder and a cutting insert assembly

FIG. 12 is a side view of the specific embodiment of FIG. 11;

FIG. 13 is a top view of the specific embodiment of FIG. 11 but withoutthe cutting insert assembly affixed to the holder, and with a portion ofthe holder body removed to show the interior coolant passage;

FIG. 14 is a cross-sectional view of the specific embodiment of FIG. 13,which does not have the cutting insert assembly, taken along sectionline 14-14 of FIG. 13;

FIG. 15 is a top view of the specific embodiment of FIG. 11 wherein thecutting insert assembly attaches to the holder;

FIG. 16 is a cross-sectional schematic view of the specific embodimentof FIG. 15 taken along section line 16-16 showing the travel of coolant,as well as the engagement of the workpiece with the cutting insert togenerate a chip;

FIG. 17 is isometric view showing the assembly of the cutting insertassembly to the holder body;

FIG. 18 is a side view of the locking pin;

FIG. 19 is a top view of the locking pin;

FIG. 20 is a cross-sectional view of the locking pin taken along sectionline 20-20 of FIG. 19;

FIG. 21 is a top view of the shim;

FIG. 22 is a cross-sectional view of the shim of FIG. 21 taken alongsection line 22-22 of FIG. 21;

FIG. 23 is an isometric view of the clamp assembly, which comprises thescrew, the clamp arm, the diverter plate and the seal;

FIG. 24 is an isometric view of the clamp assembly wherein the diverterplate is exploded away from the screw-clamp arm assembly, and the sealis exploded away from the diverter plate;

FIG. 25 is a bottom view of the diverter plate;

FIG. 25A is a top view of the diverter plate;

FIG. 26 is a cross-sectional view of the plate of FIG. 25 taken alongsection line 26-26 of FIG. 25;

FIG. 26A is a side view of another specific embodiment of the diverterplate;

FIG. 27 is a cross-sectional view of the plate of FIG. 25 taken alongsection line 27-27 of FIG. 25;

FIG. 27A is a cross-sectional view of still another specific embodimentof the diverter plate suitable for use with the clamp assembly whereinthe cross section is like that of section line 27-27 in FIG. 25;

FIG. 28 is an isometric view of the seal showing the bottom surfacethereof;

FIG. 29 is a bottom view of the seal of FIG. 28;

FIG. 30 is a cross-sectional view of the seal of FIG. 29 taken alongsection line 30-30 of FIG. 29;

FIG. 31 is an isometric view of another embodiment of a holder suitableto receive the cutting insert assembly;

FIG. 31A is an isometric view of a holder like that of FIG. 31 with theinternal coolant passage entering the holder from the rear and travelingalong the elongate shank;

FIG. 31B is an isometric view of a holder like that of FIG. 31 with theinternal coolant passage entering the holder from the side and travelingin the head of the holder;

FIG. 31C is an isometric view of a holder like that of FIG. 31 with theinternal coolant passage entering the holder from the bottom andtraveling in the head of holder;

FIG. 32 is an isometric view of a specific embodiment of a roughingcutting insert;

FIG. 32A is a cross-sectional view of the cutting insert of FIG. 32;

FIG. 33 is a top view of the cutting insert of FIG. 32;

FIG. 34 is a side view of the cutting insert of FIG. 32;

FIG. 35 is a cross-sectional view of the cutting insert of FIG. 32 takenalong section line 35-35 of FIG. 33;

FIG. 36 is a cross-sectional view of the cutting insert of FIG. 32 takenalong section line 36-36 of FIG. 33;

FIG. 37 is an isometric view of a specific embodiment of a mediumroughing cutting insert;

FIG. 37A is a cross-sectional view of the cutting insert of FIG. 37;

FIG. 38 is a top view of the cutting insert of FIG. 37;

FIG. 39 is a side view of the cutting insert of FIG. 37;

FIG. 40 is a cross-sectional view of the cutting insert of FIG. 37 takenalong section line 40-40 of FIG. 38;

FIG. 41 is a cross-sectional view of the cutting insert of FIG. 37 takenalong section line 41-41 of FIG. 38;

FIG. 42 is an isometric view of a specific embodiment of a finishingcutting insert;

FIG. 42A is a cross-sectional view of the cutting insert of FIG. 42;

FIG. 43 is a top view of the cutting insert of FIG. 42;

FIG. 44 is a side view of the cutting insert of FIG. 42;

FIG. 45 is a cross-sectional view of the cutting insert of FIG. 42 takenalong section line 45-45 of FIG. 43; and

FIG. 46 is a cross-sectional view of the cutting insert of FIG. 42 takenalong section line 46-46 of FIG. 43.

DETAILED DESCRIPTION

The present invention pertains to a cutting insert assembly useful for achipforming material removal operation, and especially to a cuttinginsert, which is a part of the above cutting insert assembly. In achipforming material removal operation, the cutting insert engages aworkpiece to remove material from a workpiece typically in the form ofchips. A material removal operation that removes material from theworkpiece in the form of chips typically is known by those skilled inthe art as a chipforming material removal operation. The book MachineShop Practice [Industrial Press Inc., New York, N.Y. (1981)] byMoltrecht presents at pages 199-204 a description, inter alia, of chipformation, as well as different kinds of chips (i.e., continuous chip,discontinuous chip, segmental chip). Moltrecht reads [in part] at pages199-200, “When the cutting tool first makes contact with the metal, itcompresses the metal ahead of the cutting edge. As the tool advances,the metal ahead of the cutting edge is stressed to the point where itwill shear internally, causing the grains of the metal to deform and toflow plastically along a plane called the shear plane . . . . When thetype of metal being cut is ductile, such as steel, the chip will comeoff in a continuous ribbon . . . ”. Moltrecht goes on to describeformation of a discontinuous chip and a segmented chip. As anotherexample, the text found at pages 302-315 of the ASTE Tool EngineersHandbook, McGraw Hill Book Co., New York, N.Y. (1949) provides a lengthydescription of chip formation in the metal cutting process. At page 303,the ASTE Handbook makes the clear connection between chip formation andmachining operations such as turning, milling and drilling. Thefollowing patent documents discuss the formation of chips in a materialremoval operation: U.S. Pat. No. 5,709,907 to Battaglia et al. (assignedto Kennametal Inc.), U.S. Pat. No. 5,722,803 to Battaglia et al.(assigned to Kennametal Inc.), and U.S. Pat. No. 6,161,990 to Oles etal. (assigned to Kennametal Inc.).

Referring to FIG. 1 of the invention, there is shown a tool holder 1having a recess 29 for receiving a cutting insert 10. The tool holder 1also has a coolant passage 2 for delivering fluid coolant to the recess29. An indexable, cutting insert 10 is positioned in the recess 29. Thecutting insert 10 has at least one flank face 12, a rake face 13 and abottom face 14. The intersection between the flank face 12 and the rakeface 13 forms a cutting edge 16. In the instance of a plurality of flankfaces, the intersection between two adjacent flank faces 12 and the rakeface 13 forms a cutting corner 17. It will be appreciated that a roundcutting insert does not include two adjacent flank faces and thereforedoes not include a cutting corner. Although a round cutting insert doesnot include a cutting corner it will be appreciated that in any case, acutting edge is present. An insert depression 15 is located in the rakeface 13 of the insert 10. The insert depression 15 is an area within therake face 13 that is lower than the remaining portion of the rake face13 surrounding the insert depression 15 and including the cutting edges16 and as appropriate, cutting corner 17. In one embodiment, the cuttingedges 16 and cutting corner all lie within the same plane. It will beapparent that some of the cutting edges may also lie above or below oneanother in elevation. For example, this would be the case if anelliptically shaped insert with an uneven rake face were used as theinsert in the metal cutting system.

The insert 10 has an insert orifice 11 that aligns with the coolantpassage 2 of the tool holder 1 to receive coolant. The insert orifice 11opens to both the rake face 13 and the bottom face 14. A top piece 18 isadjacent to insert 10. The top piece 18 has a clamp side 20 and insertside 19. Insert side 19 of top piece 18 has a shape corresponding to theinsert depression 15 such that positioning the two together forms aseal. The top piece also has a reservoir 34 (shown in FIG. 5) in theinsert side 19. The reservoir 34 is a pocket in the insert side 19 ofthe top piece 18 that aligns with the insert orifice 11. The reservoir34 distributes coolant to the top piece 18. Top piece 18 also has atleast one rake face cooling channel 21. The rake face cooling channel 21is a groove formed in the insert side 19 of the top piece 18 that runsfrom the reservoir 34 to the point on the top piece 18 nearest thecutting edge 16 or cutting corner 17, as appropriate. See FIG. 5 for aview of the rake face cooling channel 21. When the top piece 18 isseated in the insert depression 15 the rake face cooling channel 21seals against the insert depression 15 to create a coolant path tocutting edge 16 or cutting corner 17. It is also contemplated that therake face cooling channel 21 could be formed by a groove in the insertdepression 15 which seals against the insert side 19 of the top piece18. A clamp 23 applies pressure to the top piece depression 22. Theclamp 23 maintains the alignment and seal between top piece 18, insert10 and tool holder 1. It will be appreciated that the type of clamp 23is not limited to the style shown in the drawings. Rather, the clamp 23can include any other suitable clamp style of a type well known in theart.

As shown in FIG. 7 when the insert 10 engages a workpiece 30 a chip 31is lifted away from the workpiece at the cutting edge 16 or cuttingcorner 17. The congruent relationship between the top piece 18 andinsert depression 15 creates a rake face coolant cooling channel 21 thatdirects coolant so that it is delivered from an angle below theintersection at the rake face 13 and the chip 31. This delivery anglecauses the coolant to impinge the underside of the chip resulting inimproved cooling and chip removal. The rake face cooling channel 21spans from the reservoir 34 to a point nearest the cutting edge. Aprimary discharge slot 27 is formed at the end of the rake face coolingchannel 21 nearest the cutting edge 16 or cutting corner 17. It is animportant aspect of this invention that the primary discharge slot 27lie below the cutting edge 16 or corner 17. In this description, “belowthe cutting edge” or “below the cutting corner” in this descriptionmeans generally towards the recess 29 as opposed to “above the cuttingedge” or “above the cutting corner” which would be generally towards theclamp. Cooling and chip removal are most efficient when the primarydischarge slot 27 is within about 0.100 inches of the chip.

In another embodiment shown in FIG. 2 and FIG. 5, a shim 3 having a topside 8 and a bottom side 36 is positioned between the tool holder 1 andthe insert 10. The shim 3 is oriented so that the bottom side 36 abutsthe tool holder 1 and the top side abuts the insert 10. A shim pin 6 isinserted through a shim pin hole 5 and a tool holder pin hole 7. Theshim pin 6 maintains the alignment of the shim 3 between the tool holder1 and insert 10. A shim orifice 4 is formed through the center of theshim 3. The shim orifice 4 provides a path for coolant to pass from thecoolant passage 2 of the tool holder 1 to the insert orifice 11. A slotforming a part of flank face cooling channel 9 is provided on the topside 8 of the shim 3. The insert bottom face 14 seals the exposed slotin the top side 8 of shim 3 to create a flank face cooling channel 9.The flank face cooling channel 9 spans from the shim orifice 4 almost toan outer portion of the shim 3 nearest the cutting edge 16 or cuttingcorner 17. The end of flank face cooling channel 9 nearest the cuttingedge has a curved base so that coolant is directed toward the cuttingedge 16 or cutting corner 17 or flank face 12 of the insert 10.

In the embodiment as shown, the insert 10 has flank faces 12 and flankedges 32 that taper inward at a shallow angle from the rake face 13 tothe bottom face 14. In this manner the width of shim 3 will be less thanthe width of the insert bottom face 14 and less than the width of therake face 13. Attention is drawn to the fact that this taper is meant toexpose the flank faces 12 and flank edge 16 to coolant. The tapering ofthe insert 10 allows a portion of the flank face cooling channel 9 to beexposed creating secondary discharge hole 28, thus enabling expulsion ofcoolant along the flank faces of the insert 10.

A third embodiment shown in FIG. 3 adds jets 33 to the top piece 18. Thejets 33 are additional coolant conduits to increase coolant flow rateand effectively direct more fluid to the tool-chip interface. The jets33 run from the reservoir 34 to a discharge point on the clamp side 20of the top piece 18 where the coolant can be directed at the tool-chipinterface.

An alternate embodiment of the invention is shown in FIG. 4 and FIG. 6.In this embodiment, the highest coolant flow rate is achieved providingflank and rake cooling. In this assembly, a shim 3 sits in the recess 29of tool holder 1 having a tool holder pin hole 7. The shim 3 has a shimorifice 4 and a shim pin hole 5. The shim pin 6 is threaded and extendsthorough the shim pin hole 5 in to the tool holder pin hole 7 which isalso threaded. This arrangement keeps the shim 3 aligned in relation tothe recess 29. A high volume flank cooling channel 35 is formed betweenthe tool holder 1 and shim 3. Part of the high volume flank coolingchannel 35 is formed by a groove in the bottom side 36 of the shim 3.This groove could also be formed in the recess 29 of the tool holder 1.The groove is closed by the recess 29 of the tool holder 1 creating apassage for coolant delivery. The high volume flank cooling channel 35extends partway along the interface between the tool holder 1 and theshim 3 starting at the shim orifice 4 then projects through the body ofthe shim 3 toward the flank face 12 or flank edge 32 of the insert 10ending with a secondary discharge hole 28 at a corner of the shim 3closest to the cutting edge 16 or cutting corner 17 of the insert 10.

The insert 10 has tapered flank faces 12 and flank edges 32 to allow foradequate coolant wash from the secondary discharge hole 28. An insertorifice 11 aligns with the shim orifice 4. The insert bottom face 14seats against the shim 3 to create a fluid tight seal. The insertdepression 15 is frusto-conical and mates to the insert side 19 of thetop piece 18 to create a fluid tight seal. The insert side 19 of the toppiece 18 is also frusto-conical. The reservoir is located in the centralportion of the insert side 19 and is in alignment with the insertorifice 11. The alignment of the reservoir 11, insert orifice 11, shimorifice 4 and coolant passage 2 creates a chamber from which coolant canfreely flow to the high volume flank coolant channel 35, rake facecooling channel 21 and jets 33. In a preferred embodiment, the rake facecooling channel 21 runs from the reservoir 34 to within about 0.100inches of the cutting edge 16 or cutting corner 17. At the end of therake face cooling channel 21 opposite the reservoir 34 there is a nib 42on the insert side 19 of the top piece 18. The nib 42 is a bumpprotruding from the insert side that interferes with the stream ofcoolant as it exits the primary discharge slot 27. A view of the nib 42is most clearly shown in FIG. 9. The nib 42 causes the coolant to sprayin a wide pattern from the primary discharge slot 27 as opposed to aless desirable concentrated stream that occurs without the nib 42. Therake face cooling channel is sized to be large enough to maximize flowwithout permitting entry of chips into the channel. Two jets 33 run fromthe reservoir 34 to exit points on the clamp side 20 that direct thecoolant towards the cutting edge 16 or cutting corner 17. A top piecedepression 22 is present on the clamp side 20. The clamp 23 has a clamphead 24 that engages the top piece depression 22 to seat the insert 10and maintain fluid tight seals of all the coolant ducts. In a preferredembodiment, a clamp screw 25 applies pressure to the clamp head 24 inthe direction of the top piece 18. A clamp pin 26 maintains alignment ofthe clamp head 24. It will be appreciated that although a specificclamping assembly is shown in the FIGS. 1-6 and 8, any suitable clampingassembly capable of holding the top piece, insert 10 and shim 3 securelyin the recess 29 will suffice. Many of these clamping assemblies arecommercially available and well known in the art.

In the preferred embodiment, the total flow of all coolant passagesshould not be less than 80% of the possible flow from an unrestrictedflood nozzle. There should be an appreciation that any one of a numberof different kinds of fluid or coolant are suitable for use in thecutting insert. Broadly speaking, there are two basic categories offluids or coolants; namely, oil-based fluids which include straight oilsand soluble oils, and chemical fluids which include synthetic andsemisynthetic coolants. Straight oils are composed of a base mineral orpetroleum oil and often contain polar lubricants such as fats, vegetableoils, and esters, as well as extreme pressure additives of chlorine,sulfur and phosphorus. Soluble oils (also called emulsion fluid) arecomposed of a base of petroleum or mineral oil combined with emulsifiersand blending agents Petroleum or mineral oil combined with emulsifiersand blending agents are basic components of soluble oils (also calledemulsifiable oils). The concentration of listed components in theirwater mixture is usually between 30-85%. Usually the soaps, wettingagents, and couplers are used as emulsifiers, and their basic role is toreduce the surface tension. As a result they can cause a fluid tendencyto foam. In addition, soluble oils can contain oiliness agents such asester, extreme pressure additives, alkanolamines to provide ÒreservealkalinityÓ, a biocide such as triazine or oxazolidene, a defoamer suchas a long chain organic fatty alcohol or salt, corrosion inhibitors,antioxidants, etc. Synthetic fluids (chemical fluids) can be furthercategorized into two subgroups: true solutions and surface activefluids. True solution fluids are composed essentially of alkalineinorganic and organic compounds and are formulated to impart corrosionprotection to water. Chemical surface-active fluids are composed ofalkaline inorganic and organic corrosion inhibitors combined withanionic non-ionic wetting agents to provide lubrication and improvewetting ability. Extreme-pressure lubricants based on chlorine, sulfur,and phosphorus, as well as some of the more recently developed polymerphysical extreme-pressure agents can be additionally incorporated inthis fluids. Semisynthetics fluids (also called semi-chemical) containsa lower amount of refined base oil (5-30%) in the concentrate. They areadditionally mixed with emulsifiers, as well as 30-50% of water. Sincethey include both constituents of synthetic and soluble oils,characteristics properties common to both synthetics and water solubleoils are presented.

It will be appreciated that some handling benefits have been seen whenthe top piece 18 is fixed to the clamp 23. This arrangement reduces thechance that an operator will inadvertently drop the top piece whenremoving or installing the assembly. The most effective means of fixingthe top piece 18 to the clamp 23 is with a slotted spring pin 39. Theslotted spring pin 39 is inserted into a clamp bore 40 and a top piecebore 41 which are aligned as seen in FIG. 8. Although other means offastening the pieces together are possible, the use of a slotted springpin 39 allows for some rotation of the top piece 18 about the main axisof the slotted spring pin 39. This arrangement allows the top piece 18to be aligned with the differing orientations of the insert 10.

A centering stud 43 can be included between the top piece 18 and insert10. The centering stud 43 seats into the reservoir 34 and extends intothe insert orifice 11. The shape of the centering stud conforms to theboundaries of the reservoir 34 and the insert orifice 11 and in this waythe centering stud 43 acts as an alignment device. The centering studhas an open interior so that coolant flow is not restricted. FIG. 9shows a centering stud fixed in the reservoir 34 of the top piece 18 andFIG. 10 is an isolated view of a centering stud. For illustrativepurposes, the insert 10 is not shown in FIG. 9.

Referring to FIG. 11 as well as other appropriate drawings, FIG. 11 isan isometric view that shows another specific embodiment of the cuttingassembly generally designated as 100. This is a cutting assembly usefulfor an operation for chipforming removal of material from a workpiece.Cutting assembly 100 comprises the basic components of a holder 102,which is a style holder sold by Kennametal Inc., Latrobe, Pa. USA 15650under the trademark KM. There should be an appreciation that differentstyles of holders are suitable for use. The holder should have aninternal coolant delivery passageway, which communicates with a coolantsource, and a seating region. The seating region has an opening in theseat wherein the opening is in fluid communication with the internalcoolant passageway. The cutting assembly 100 further includes a shim104, a locking pin 106, a cutting insert 108, and a clamp assembly 110.The clamp assembly 110 comprises an upstanding screw 112 and an arm 114,which projects away from the screw 112. A diverter plate 116 detachablyconnects to the arm 114, wherein at least a portion of the diverterplate 116 projects away from the arm 114 and covers at least a portionof the cutting insert 108. The clamp assembly 110 further includes aseal member 118, which has a resiliency so when under compressioncreates a seal with the diverter plate 116 and also creates a seal withthe cutting insert 108.

Arrows CF in FIG. 11 represents the coolant flow spraying or exitingfrom the cutting assembly. The coolant sprays toward the discretecutting location where the cutting insert engages the workpiece. As willbe described in more detail hereinafter, the coolant spray moves alongthe radial coolant trough in the rake surface of the cutting insert. Thegeometry of the radial coolant trough causes the coolant to move in theupward direction away from the rake face and the outward direction awayfrom the central insert aperture. The coolant exits the radial coolanttrough in an upward and outward direction. The coolant spray impingesthe underneath surface of the chip formed from the workpiece wherein theupward and outward movement of the coolant facilitates the impingementof the chip on the underneath surface thereof.

Referring to FIGS. 12 through 14 as well as other appropriate drawings,the holder 102 has a holder body 124, which has a forward end (orworking end) 128 and a rearward end 126. The holder body 124 has a shankregion (bracket 130) adjacent the rearward end 126 and a head region(bracket 132) adjacent the forward end 128. The head region 132 includesa seat generally designated as 136, which has a seating surface 138 andan upstanding support surface 140. As will become apparent hereinafter,the upstanding support surface 140 provides support for the shim and thecutting insert when secured to the seat 136.

The holder body 124 contains a coolant delivery passage 142, which hasone end 144 and an opposite end 146. The opposite end 146 is in theseating surface 138. The coolant delivery passage 142 has a smoothfrusto-conical section 147 adjacent the seating surface 138. The coolantdelivery passage 142 further has a threaded section 148 next to thesmooth frusto-conical section 147. See FIG. 14. In reference to thecoolant delivery passage 142, the majority of the passage 142 comprisesa generally cylindrical conduit 150 that moves from the one end 144 to apoint 151 where the passage 142 changes direction. A shorter portion 152of the passage 142 then travels to the seating surface 138. Coolantenters the coolant delivery passage 142 through the one end 144. SeeFIG. 13.

Referring to FIGS. 21 and 22 as well as other appropriate drawings, theshim 104 has a generally polygonal geometry with a top surface 154, abottom surface 156, and a flank surface 158. The shim 104 contains acentral aperture 160 passing completely through the shim 104. Thecentral aperture 160 has an annular lip 162 mediate the top surface 154and the bottom surface 156 wherein the lip 162 projects into the volumeof the central aperture 160. Annular lip 162 has a generallyfrusto-conical surface in cross-section. As will described in moredetail hereinafter, the annular lip 162 provides a surface against whichan O-ring seal deforms under compression to create a fluid-tight sealbetween the shim 104 and the locking pin 106. There should be anappreciation that the shim 104 may contain or cooperate with otherstructure, which performs the sealing function. Applicants do notcontemplate that an O-ring is the only way to create the seal betweenthe shim 104 and the locking pin 106.

Referring to FIGS. 18-20 as well as other appropriate drawings, thelocking pin 106 has an elongate locking pin body 170, which has an axialtop end 172 and an axial bottom end 174. Locking pin body 170 contains acentral longitudinal bore 176 extending all the way through the lockingpin body 170. The longitudinal bore 176 has a coolant inlet 178 and acoolant outlet 180. as will become apparent hereinafter, coolant entersat the coolant inlet 178, travels through the bore 176, and exits at thecoolant outlet 180. The exterior surface of the locking pin body 170 hasan annular shoulder 182 mediate of the axial top end 172 and the axialbottom end 174. Rearward of the shoulder 182 is an annular arcuategroove 183. The locking pin body 170 has a head region (bracket 184)adjacent the top end 172 and a shank region (bracket 186) adjacent thebottom end 174. The arcuate groove 183 in the locking pin body 170carries a resilient O-ring seal 188. The exterior surface of the lockingpin body 170 contains a threaded region 200 adjacent the bottom end 174thereof. The locking pin body 170 further has a forward annular shoulder202.

The locking pin 106 provides for a “pull back” feature upon completetightening into the threaded section 148 of the coolant delivery passage142. The locking pin 106 accomplishes this feature by a difference inthe orientation of the longitudinal axis of the threaded section 200 ascompared to the longitudinal axis of the remainder of the locking pin170. FIGS. 18 and 20 illustrate this difference in orientation. In thesedrawings, the central longitudinal axis of the threaded region 200 andthe longitudinal axis of the remainder of the locking pin are disposedapart an angle “Z”. By “pull back”, it is meant that upon completetightening of the lock pin 106, the lock pin 106 urges the shim 104 andthe cutting insert 108 toward the upstanding support surface 140. Thisfeature enhances the integrity of the holding of the cutting insert 108and shim 104 in the seat of the holder.

In reference to the specific cutting inserts, there are three basiccutting inserts; namely, the roughing cutting insert 420, the roughingmedium cutting insert 422, and the finishing cutting insert 424. As willbecome apparent, each one of these cutting inserts (420, 422, 424),which is for use in a chipforming material removal operation, has acutting insert body that has a seating surface and a flank face. Thereis a corner cutting region, which is at the intersection of theperipheral edge region and the flank face adjacent corresponding cornersthereof, that has a peripheral edge. For the roughing insert 420, thecorner cutting region 432 is at the intersection of the centralperipheral edge region 452 and a pair of lateral peripheral edge regions454, 456, and the adjacent flank face. For the medium roughing insert422, the corner cutting region 532 is at the intersection of the centralperipheral edge region 552 and a pair of lateral peripheral edge regions554, 556, and the flank face. For the finishing insert 424, the cornercutting region 632 is at the intersection of the central peripheral edgeregion 652 and a pair of lateral peripheral edge regions 654, 656, andthe flank face. As will become apparent from the descriptionhereinafter, each one of the cutting inserts (420, 422, 424) has eightseparate discrete corner cutting regions.

For each of the cutting inserts, the cutting insert body contains acentral aperture that opens at the opposite seating surfaces. Thecentral aperture has a mediate cylindrical section, which is bounded bya pair of frusto-conical mouth sections adjacent each seating surface.

As will be discussed hereinafter, for each one of the cutting inserts(420, 422, 424), the mediate cylindrical section of the central aperturehas the same diameter. In these specific embodiments, the diameter ofthe mediate cylindrical section is equal to about 7.68 millimeters (mm).Further, in this specific embodiment, the frusto-conical surface thatdefines the frusto-conical mouth has a included angle equal to about84°, 12′. By providing a mediate cylindrical section and frusto-conicalmouth section with the same dimensioning, applicants have been able todevelop a set of cutting inserts (420, 422, 424) that fit within a seatin one tool holder. It is advantageous to provide such a set of cuttinginserts, which are useful for different applications, that can be usedwith a single tool holder.

The seating surface contains a coolant delivery trough that has a radialorientation toward a corresponding corner cutting region. The coolantdelivery trough has a radial outward end terminating at the peripheraledge and a radial inward end opening into the central aperture. Thecutting insert has a pair of lateral topographic regions wherein the onelateral topographic region is along one side of the coolant deliverytrough and the other lateral topographic region is along other side ofthe coolant delivery trough.

FIGS. 32-36 illustrate the roughing cutting insert 420. FIGS. 37-41illustrate the medium roughing cutting insert 422. FIGS. 42-46illustrate the finishing cutting insert 424. Further, applicants notethat the roughing cutting insert is shown in co-pending U.S. Designpatent application Ser. No. 29/369,123 filed Sep. 2, 2010 for CUTTINGINSERT by Chen et al. [K-3063]. The medium roughing insert is shown inco-pending U.S. Design patent application Ser. No. 29/369,124 filed Sep.2, 2010 for CUTTING INSERT by Chen et al. [K-3064]. The finishing insertis shown in co-pending U.S. Design patent application Ser. No.29/369,125 filed Sep. 2, 2010 for CUTTING INSERT by Chen et al.[K-3065]. Applicants hereby incorporate by reference herein in theirentirety the above-identified U.S. Design patent applications (Ser. No.29/369,123, Ser. No. 29/369,124, and Ser. No. 29/369,125). A moredetailed description of the cutting inserts now follows using FIGS.32-46.

Referring to FIGS. 32-36, the roughing insert 420 has a roughing insertbody 430 with a diamond-shaped geometry having eight discrete cornercutting regions 432. The roughing insert body 430 has a pair of oppositeseating surfaces 434, 436 and a flank face 438, which extends about theperiphery of the roughing insert body 430. As will be describedhereinafter, when the roughing insert 420 is assembled to the cuttingtool holder, one of the seating surfaces contacts the shim and the otherseating surface contacts the diverter plate to create a seal therewith.The flank face 438 intersects the central peripheral edge region 452 andthe pair of lateral peripheral edge regions 454, 456 to form cuttingedges 440 at the corner cutting regions 432. One opposite pair of cornercutting regions 432 (upper right hand corner and lower left hand corneras viewed in FIG. 33) has an included angle “AAA” equal to about 80°.The other opposite pair of corner cutting regions 432 (upper left handcorner and lower right hand corner as viewed in FIG. 33) has an includedangle “BBB” equal to about 100°. The structural features including thesurfaces are essentially the same for each corner cutting region 432.The length of one side (and its opposite side) as measured by dimension“DD” in FIG. 33 is equal to 12.90 mm. The length of the other side (andits opposite side) as measured by dimension “EE” in FIG. 33 is equal to12.70 mm.

The roughing insert body 430 contains a central aperture 444 that passesthrough the roughing insert body 432 whereby the central aperture 444intersects both seating surfaces (434, 436). The central aperture 444has a mouth (446, 448) at each one of the intersections with the seatingsurfaces (434, 436). The central aperture 444 has a generallycylindrical section between the mouths 446, 448.

Referring to FIG. 32A, in this specific embodiment, the mouth, which hasa generally frusto-conical shape, has an included angle “HH”. In thisspecific embodiment, the angle HH is equal to 84° 12′. Referring to FIG.33, in this specific embodiment, the diameter FF of the mediatecylindrical section is equal to about 7.68 mm.

There is a peripheral edge 450 that extends about the corner cuttingregion 432. The peripheral edge 450 is below the seating surface plane.FIG. 36 shows that the peripheral edge 450 is a distance “D” below theseating surface plane. The peripheral edge 450 has a central peripheraledge region 452 and a pair of lateral peripheral edge regions 454, 456that extend away from the central peripheral edge region 452. The cornercutting region 432 may comprise all of or a part of the peripheral edge450, depending upon the specific cutting operation. The corner cuttingregion 450 typically includes the central peripheral edge region 452.

At each corner cutting region 432 is a radial coolant trough 460. Theradial coolant trough 460 has a radial inward end 462 that opens intothe central aperture 444. In this embodiment, the radial coolant trough460 does not intersect the cylindrical section of the central aperture444. The radial coolant trough 460 has an arcuate bottom surface 464 andlateral flat side surfaces 466, 468 that terminate in lateral side edges470, 472, respectively. There are smooth transitions between the arcuatesurface and the flat side surface so as to facilitate the smooth andeffective delivery of coolant through the radial coolant trough. Theradial coolant trough 460 has a radial outward end 478 that terminatesat a central notch 484 between the radial coolant trough 460 and thecentral peripheral edge 452. As shown in FIG. 36, in this specificembodiment, the peripheral edge region can be disposed at a rake angle(GG) between about 0 degrees and +5 degrees. As is apparent from thedrawings, the arcuate bottom surface 464 of the radial coolant trough460 moves toward the rake surface in the radial outward direction. Inother words, the depth of the radial coolant trough 460 decreases as thetrough 460 in the radial outward direction.

A lateral topographic region is along each lateral side edge of theradial coolant trough. There is a pair of peripheral notches 480, 482that run along and are inside of the lateral peripheral edges 454, 456,except that the peripheral notches 480, 482 terminate at theirintersection with the radial coolant trough 460.

Referring to FIGS. 37-41, the medium roughing cutting insert 520 has amedium roughing cutting insert body 530 with a diamond-shaped geometryhaving eight discrete corner cutting regions 532. The medium roughingcutting insert body 530 has a pair of opposite seating surfaces 534, 536and a flank face 538, which extends about the periphery of the mediumroughing cutting insert body 530. As will be described hereinafter, whenthe medium roughing insert 422 is assembled to the cutting tool holder,one of the seating surfaces contacts the shim and the other seatingsurface contacts the diverter plate to create a seal therewith. Theflank face 538 intersects the central peripheral edge region 552 and thepair of lateral peripheral edge regions 554, 556 to form cutting edges540 at the corner cutting regions 532. One opposite pair of cornercutting regions 532 (upper right hand corner and lower left hand corneras viewed in FIG. 38) has an included angle “CCC” equal to about 80°.The other opposite pair of corner cutting regions 532 (upper left handcorner and lower right hand corner as viewed in FIG. 38) has an includedangle “DDD” equal to about 100°. The structural features including thesurfaces are the same for each corner cutting region 532. In thisspecific embodiment, the length of one side (and its opposite side) asmeasured by dimension “II” in FIG. 38 is equal to 12.90 mm. In thisspecific embodiment, the length of the other side (and its oppositeside) as measured by dimension “JJ” in FIG. 38 is equal to 12.70 mm.

The medium roughing cutting insert body 532 contains a central aperture544 that passes through the medium roughing cutting insert body 532whereby the central aperture 544 intersects both seating surfaces (534,536). The central aperture 544 has a mouth (546, 548) at each one of theintersections with the seating surfaces (534, 536). The central aperture544 has a generally cylindrical section between the mouths 546, 548.Referring to FIG. 37A, in this specific embodiment, the mouth, which hasa generally frusto-conical shape, has an included angle “MM”. In thisspecific embodiment, the angle MM is equal to 84° 12′. Referring to FIG.38, the diameter KK of the mediate cylindrical section is equal to about7.68 mm.

There is a peripheral edge 550 that extends about the corner cuttingregion 532. The peripheral edge 550 is below the seating surface plane.FIG. 41 shows the peripheral edge 650 is a distance “E” below theseating surface plane. The peripheral edge 550 has a central peripheraledge region 552 and a pair of lateral peripheral edge regions 554, 556that extend away from the central peripheral edge region 552.

At each corner cutting region 532 is a radial coolant trough 560. Theradial coolant trough 560 has a radial inward end 562 that opens intothe central aperture 544. In this embodiment, the radial coolant trough560 does not intersect the cylindrical section of the central aperture544. The radial coolant trough 560 has an arcuate bottom surface 564 andlateral side surfaces 566, 568 that terminate in lateral side edges 570,572, respectively. There are smooth transitions between the arcuatesurface and the flat side surface so as to facilitate the smooth andeffective delivery of coolant through the radial coolant trough. Theradial coolant trough 560 has a radial outward end 578 that terminatesat the central peripheral edge region 552. As shown in FIG. 41, in thisspecific embodiment, the peripheral edge region can be disposed at arake angle (LL) between about +10 degrees and +14 degrees. As isapparent from the drawings, the arcuate bottom surface 564 of the radialcoolant trough 560 moves toward the rake surface in the radial outwarddirection. In other words, the depth of the radial coolant trough 560decreases as the trough 560 in the radial outward direction.

A lateral topographic region is along each lateral side edge of theradial coolant trough. There is a lateral notch 580 to each side of andspaced slightly apart from the radial coolant trough 560. Each lateralnotch 580 has a forward-facing beveled face 582. The peripheral edge 550terminates at the forward-facing beveled face 582. The notch 580 alsohas a beveled lateral face 584 that runs parallel to the radial coolanttrough 560, and which decreases in area from the intersection with theforward-facing beveled face 582 and its forward point of termination atthe peripheral edge 550.

Referring to FIGS. 42 through 46, the finishing insert 424 has afinishing insert body 630 with a diamond-shaped geometry having eightdiscrete corner cutting regions 632. The finishing insert body 630 has apair of opposite seating surfaces 634, 636 and a flank face 638, whichextends about the periphery of the finishing insert body 630. As will bedescribed hereinafter, when the finishing insert 424 is assembled to thecutting tool holder, one of the seating surfaces contacts the shim andthe other seating surface contacts the diverter plate to create a sealtherewith. The flank face 638 intersects the central peripheral edgeregion 652 and the pair of lateral peripheral edge regions 654, 656 toform cutting edges 640 at the corner cutting regions 632. One oppositepair of corner cutting regions 632 (upper right hand corner and lowerleft hand corner as viewed in FIG. 43) has an included angle “EEE” equalto about 80°. The other opposite pair of corner cutting regions 632(upper left hand corner and lower right hand corner as viewed in FIG.43) has an included angle “FFF” equal to about 100°. The structuralfeatures including the surfaces are the same for each corner cuttingregion 632. In this specific embodiment, the length of one side (and itsopposite side) as measured by dimension “OO” in FIG. 43 is equal to12.90 mm. In this specific embodiment, the length of the other side (andits opposite side) as measured by dimension “PP” in FIG. 43 is equal to12.70 mm.

The finishing insert body 632 contains a central aperture 644 thatpasses through the finishing insert body 632 whereby the centralaperture 644 intersects both seating surfaces (634, 636). The centralaperture 644 has a mouth (646, 648) at each one of the intersectionswith the seating surfaces (634, 636). The central aperture 644 has agenerally cylindrical section between the mouths 646, 648. Referring toFIG. 43A, in this specific embodiment, the mouth, which has a generallyfrusto-conical shape, has an included angle “SS”. In this specificembodiment, the angle SS is equal to 84° 12′. Referring to FIG. 43, inthis specific embodiment, the diameter QQ of the mediate cylindricalsection is equal to about 7.68 mm.

There is a peripheral edge 650 that extends about the corner cuttingregion 632. The peripheral edge 650 is below the seating surface plane.FIG. 46 illustrates that the peripheral edge 650 is a distance “F” belowthe seating surface plane. The peripheral edge 650 has a centralperipheral edge region 652 and a pair of lateral peripheral edge regions654, 656 that extend away from the central peripheral edge region 652.

At each corner cutting region 632 is a radial coolant trough 660. Theradial coolant trough 660 has a radial inward end 662 that opens intothe central aperture 644. In this embodiment, the radial coolant trough660 does not intersect the cylindrical section of the central aperture644. The radial coolant trough 660 has an arcuate bottom surface 664 andlateral side surfaces 666, 668 that terminate in lateral side edges 670,672, respectively. The radial coolant trough 660 has a radial outwardend 678 that terminates at the central peripheral edge region 652. Asshown in FIG. 46, in this specific embodiment, the peripheral edgeregion can be disposed at a rake angle (RR) between about +12 degreesand +15 degrees. As is apparent from the drawings, the arcuate bottomsurface 664 of the radial coolant trough 660 moves toward the rakesurface in the radial outward direction. In other words, the depth ofthe radial coolant trough 660 decreases as the trough 660 in the radialoutward direction.

A lateral topographic region is along each lateral side edge of theradial coolant trough. There is a lateral notch 680 to each side of theradial coolant trough 660. Each lateral notch 680 has a forward-facingbeveled face 682. The peripheral edge 650 terminates at theforward-facing beveled face 682. The lateral notch 680 also has alateral face 684 that runs parallel to the radial coolant trough 660,and which decreases in area from the intersection with theforward-facing beveled face 682 and its forward point of termination atthe peripheral edge 650. There is a pair of small projections 688 on thelateral face 684, which extend from the joinder with the radial coolanttrough 660. The small projections 688 help prevent the chips fromentering the radial coolant trough. Further, the small projectionsfacilitate the breakage of chips. The size and orientation and number ofthe projections may vary to accommodate different applications.

For each cutting insert, it is apparent that the radial coolant troughhas an origin proximate to the central cutting insert aperture and atermination proximate to and spaced radially inward from the cornercutting edge region. The radial coolant trough has a depth decreasingfrom the origin to the termination. The coolant when exiting the radialcoolant trough travels in an upward direction away from the rakesurface.

Referring to FIGS. 28-30 as well as other appropriate drawings, the sealmember 118 has a generally circular body 250, which has a centralaperture 252 and a circumferential edge 254. The top surface 256 of thegenerally circular body 250 is generally flat and the bottom surface 258is generally frusto-conical in shape. A generally cylindrical topupstanding collar 262 projects away from the flat top surface 256 of thegenerally circular body 250. The top upstanding collar 262 has a distalcircular edge 264.

There is an opening 266 in the collar and a corresponding opening 268 inthe generally circular body 250. The combination of these openings (266,268) permits the flow of coolant (see arrows CF in FIG. 28) to thecutting insert as will be described hereinafter. The frusto-conicalbottom surface 258 has a generally circular terminal edge 276. Thediameter (X in FIG. 30) of the circular opening defined by the circularterminal edge 276 is larger than the diameter (Y in FIG. 30) of thecircular opening defined by the distal circular edge 264 of theupstanding collar 262.

As one alternative, seal 118 is made of a resilient material such as aplastic material that is compressible to form a fluid-tight seal. Theremay be other alternative materials, which are not necessarily plastics,but which provide for the necessary resilience or compressibility tocreate the seal when under compression. As will be describedhereinafter, the seal 118 creates a seal with each one of the diverterplate 116, the locking pin 106 and the cutting insert 108.

Referring to FIGS. 23-24 as well as other appropriate drawings, theclamp assembly 110 includes the screw 112, which has an upper end 280and a lower end 282. The screw 112 has a head portion 284 and a threadedsection 286. The clamp assembly 110 further includes the arm 114. Thearm 114 has a proximate end 300 and a distal end 302. The arm 114 alsohas a base section 304, which contains an aperture 306, adjacent to theproximate end 300. The base section 304 also has a cylindrical section305. The screw 112 is rotatable within the aperture 306 of the basesection 304. The head portion 284 and a C-shaped resilient split ring(or clip) 287 retain the screw 112 in the aperture 306.

The arm 114 further has a finger section 312, which is integral with thebase section 304, extends toward the cutting insert when the componentsare in the assembled condition. The finger 312 terminates at the distalend 302 of the clamp arm 114. The clamp arm 114 has a bottom surface314, which defines a central shoulder 316 and a pair of opposite lateralrecesses 318, 320.

Referring to FIGS. 25 through 27, as well as other appropriate drawings,the clamp assembly 110, which attaches to the holder and engages thecutting insert, further has a diverter plate 116, which has a proximateend 330, which is closest to the arm 114 and a distal end 332, which isfarthest from the arm 114. The diverter plate 116 also has a top surface334. The top surface 334 has a flat surface portion 336, which containsa central groove 338 therein. The top surface 334 further has a beveledsurface portion 342 wherein a channel 340 separates the flat surfaceportion 336 from the beveled surface portion 342. The beveled surfaceportion 342 contains a pair of lateral surfaces 346, 348 and a centralsurface 350. The diverter plate 116 contains a central notch 352 in thecentral surface 350 at the distal end 332. The diverter plate 116 has apair of opposite side surfaces 354, 356. Each side surface (354, 356)has a flat surface portion 360 and a notch portion 362. Each notchportion 362 has a flat portion 364 and a beveled portion 366. Thediverter plate 116 has a bottom surface 370, which contains a generallycircular depression or bowl 372 and an elongate channel 376, whichextends away from the depression 370 toward the central notch 352.

The head portion 284 has a pair of spaced-apart prongs 288 that extendoutwardly toward the cutting insert when the components are in theassembled condition. The prongs 288 have a generally inward bias. Theprongs engage the diverter plate 116 to retain the diverter plate 116 tothe clamp arm 114. More specifically, to assemble the diverter plate 116to the clamp arm 114, the diverter plate 116 is positioned in alignmentwith the prongs 288. The beveled surface 366 at the proximate end 330engage the prongs to spread them apart as the diverter plate 116 movestoward the cylindrical member 305. The prongs 288 bias inward toward thediverter plate 116 and are within the notches 362. The inward bias ofthe prongs 288 securely retains the diverter plate to the clamp arm 114.As one can appreciate, the diverter plate 116 can be detached from theclamp arm 114 by pulling the diverter plate 116 away from the base 304.By providing a diverter plate that easily attaches to the remainder ofthe clamp assembly, the material from which the diverter plate is madecan vary, depending upon the cutting application. For example, thediverter plate 116 can be made of steel or carbide, depending upon thespecific application. The capability to vary only the material of thediverter plate without changing the remainder of the clamping assemblyis an advantage.

FIG. 26A illustrates an alternative diverter plate 116′ that has abottom surface 370′ with an orientation such that the bottom surface370′ slopes away from the diverter plate body at an angle “H”, which isequal to about 7 degrees. However, there should be an appreciation thatangle “H” can vary depending upon the specific application orcircumstance. Because of the orientation of the bottom surface 370′,during the clamping process, the proximate end 331 first contacts thecutting insert prior to the balance of the plate contacting the cuttinginsert. This contact facilitates the seating of the seal on the cuttinginsert and the sealing between the cutting insert and the seal.

FIG. 27A illustrates another specific embodiment of the diverter plate116A. The structure of the diverter plate 116A is the same as that ofthe diverter plate 116, except that the surfaces that help define thebowl are disposed at an angle “1” equal to about 90° to the adjacentsurface of the bowl. This is in contrast to diverter 116 in which thesurfaces that help define the bowl are disposed to the adjacent surfaceof the bowl at an angle “J” equal to about 10 degrees. However, thereshould be an appreciation that angle “J” can vary depending upon thespecific application or circumstance.

Another specific embodiment combines the diverter plate and the sealinto a one piece integral diverter plate. More specifically, thisembodiment of the modified diverter plate has the same structuralfeatures as the diverter plate 116 and an integral protrusion that hasthe same structure as the seal 118. The integral protrusion has acoating thereon. The coating has elastomeric properties so uponcompression, the coating creates a fluid-tight seal with the surface(s)that it contacts.

Referring to the assembly of the components, FIG. 17 provides a visualguide to the assembly of the components. Initially, the shim 104 ispositioned on the seating surface 138 of the seat 136 in the holder 102.The flank surfaces 158 of the shim 104 adjacent the upstanding wall 140contact the surface of the wall 140. Arrow AA represents this step inthe assembly process.

As the next step, the locking pin 106 is inserted into the outlet 146 ofthe coolant delivery passage 142 in the seating surface 138. Thethreaded region 200 of the locking pin 106 threadedly engages thethreaded section 148 of the coolant delivery passage 142. The lockingpin 106 is threaded until it is tightly secured in the coolant deliverypassage 142. As is apparent, at least a part of the locking pin 106 isin the coolant delivery passage 142. The locking pin 106 tightly securesshim 104 to the seating surface of the seat. Arrows BB represent thisstep in the assembly process.

There should be an appreciation that once the locking pin 106 issecurely affixed in the coolant delivery passage 142, the rearwardsurface of the shoulder 182 compresses the O-ring 188 against the lip162 of the shim 104. The O-ring 188 creates a fluid-tight seal betweenthe locking pin 106 and the shim 104. During operation, coolant cannotescape between the shim and locking pin.

As the next step, the cutting insert 108 is positioned on top of theshim 104. When in this position, the upper portion of the locking pin106 is at least within some of the central aperture of the cuttinginsert 108. The frusto-conical mouth 220, which surrounds the centralcutting insert aperture 219, tightly rests on the forward annularshoulder 202 of the locking pin 106 to form a fluid-tight seal. ArrowsCC represent this step in the assembly process.

The next step in the assembly process comprises attaching the clampassembly 110 to the holder 102. The threaded section 286 of the screw112 threadedly engages the threaded clamp bore 153 in the holder 102.The clamp assembly 110 is tightened down into position where it retainsthe cutting insert 108 in position on top of the shim 104. As previouslymentioned, the use of a diverter plate with a sloped surface facilitatesthe seating and sealing of the seal with respect to the cutting insert.In this regard, FIG. 26A illustrates the diverter plate 116′ with asloped rearward surface 370′. The rearward surface 370′ slopes towardthe cutting insert when the clam assembly is attached to the holder 102.

When in the securely tight position, the seal 118 compresses against thecutting insert 108 to form a fluid-tight seal with the cutting insert.The seal 118 also compresses against the bottom surface of the diverterplate 116 to form a fluid-tight seal with the diverter plate. As one canappreciate, the seal (seal member) 118 is mediate of the cutting insertand the diverter plate. The seal 118 provides a fluid-tight seal betweenthe cutting insert and the diverter plate, and the seal member furtherprovides a fluid-tight seal between the cutting insert and the lockingpin. At this stage in the assembly process, the cutting assembly isready to perform in an operation for chipforming removal of materialfrom a workpiece.

In operation, the coolant, which is typically under pressure, enters thecoolant delivery passage 142 via the one end 144. Coolant travelsthrough the coolant delivery passage 142 towards the seating surface138. The locking pin 106 is threaded fully into the coolant deliverypassage 142 adjacent the other end 144 thereof. When in this condition,the axial bottom end 174 of the locking pin 106 is located into thecoolant delivery passage 142. Coolant enters through the inlet 178 intothe longitudinal bore 176 of the locking pin 106. Coolant flows throughthe longitudinal bore 176 and exits through the outlet 180 into the bowlof the diverter plate. In other words, the longitudinal locking pin boreopens to the diverter plate whereby coolant flows into the diverterbowl.

There should be an appreciation that when the locking pin 106 isthreaded fully in the coolant delivery passage 142, there are severallocations that provide fluid-tight seals which help contain the coolant.The threads engage the threaded portion to create a fluid-tight seal to,at least, provide an engagement that restricts the leakage of coolant atthe threaded portion of the coolant delivery passage 142. The lockingpin body 170 is pressed firmly against the smooth frusto-conical surfaceof the coolant delivery passage 142 adjacent the other end 146 thereof.The surface-to-surface engagement is tight to create a fluid-tight sealbetween the locking pin 106 and the smooth frusto-conical surface thatdefines the coolant delivery passage 142. The bottom surface of the shimis pressed tightly against the surface of the seat to provide a tightsurface-to-surface engagement, which provides a fluid-tight seal.Finally, upon being compressed between the shim and the locking pin, theresilient O-ring 188 provides a fluid-tight seal between the shim andthe locking pin so coolant cannot escape.

It is therefore apparent that there are multiple sealing points thatprovide fluid-tight seals. These seals comprise a locking pin-coolantdelivery passage seal at the threaded portion, a locking pin-coolantdelivery passage seal at the frusto-conical smooth surface, ashim-seating surface seal, and a locking pin-shim seal due to theO-ring. These multiple seals provide sealing integrity so little oressentially no coolant escapes as it travels from the coolant deliverypassage into and through the locking pin.

As mentioned above, coolant flows through the longitudinal bore 176 ofthe locking pin 106 into the bowl (or depression) 372 of the diverterplate 116. The bowl 372, which has a generally circular geometry,receives the upstanding collar 262 of the seal 118. The dimensioning ofthe bowl 372 and the upstanding collar 262 is such so under compression,the seal 118 provides a fluid-tight connection with the diverter plate116 at the locations of actual contact. As described hereinabove, thereis an opening in the upstanding collar where the seal does not contactthe diverter plate, and thus, there is an absence of a fluid-tight sealat this location. Coolant flows out of the seal opening (266, 268) tothe diverter channel and then to the radial coolant trough of thecutting insert toward the corner cutting region.

When under compression, the seal 118 provides a fluid-tight seal withthe cutting insert. More specifically, the frusto-conical surface 258 ofthe seal 118 compressively contacts the mouth of the central aperture tocreate a fluid-tight seal. Further, when under compression, the terminalcircular edge 276 of the frusto-conical surface 258 compresses againstthe axial forward end of the locking pin 106. This compressiverelationship between terminal circular edge 276 of the seal and theaxial forward end of the locking pin creates a fluid-tight seal betweenthe locking pin and the seal.

There should be an appreciation that there is a high degree of integrityin the containment of coolant as it exits the locking pin. There is afluid-tight seal between the seal and the diverter plate, except forwhere the opening exists in the seal. There is a fluid-tight sealbetween the seal and the cutting insert. Finally, there is a fluid-tightseal between the seal and the locking pin.

Overall, it is apparent that there is a high of degree of integrity onthe containment of coolant throughout the complete travel of coolantfrom the coolant delivery passage until it reaches the bowl in thediverter plate. The multiple points of fluid-tight seals comprise: alocking pin-coolant delivery passage seal at the threaded portion, alocking pin-coolant delivery passage seal at the frusto-conical smoothsurface, a shim-seating surface seal, a locking pin-shim seal due to theO-ring, a seal-diverter plate seal via the upstanding collar, aseal-cutting insert seal adjacent the mouth surrounding the centralaperture of the cutting insert, and a seal-locking pin seal adjacent theaxial forward end of the locking pin.

Coolant flows out of the seal 118 via openings 266, 268 into the channel376 of the diverter plate. The coolant travels through the channel 376in a radial outward direction to where it exits the channel 376 adjacentthe notch 350.

The cutting insert has an orientation relative to the coolant channel376 and the notch 350 that upon exiting the channel 376, the coolantenters the radial coolant trough. There should be an appreciation thatthis is the case for any one of the three cutting inserts describedhereinabove; namely, the roughing insert, the medium roughing insert andthe finishing insert. Coolant then flows through the radial elongatechannel exiting at the termination thereof to spray or jet toward thecorner cutting edge region.

The coolant spray travels in a direction upward and outward from theradial coolant trough in the rake surface of the cutting insert. Thecoolant spray impinges the underneath surface of the chip formed fromthe workpiece during the cutting operation.

FIG. 31 is an isometric view of another embodiment of a holder suitableto receive the cutting insert assembly. This holder 390 has a holderbody 391 with opposite axial forward end 392 and an axial rearward end393. A shank 396 is adjacent the rearward end 393 and a head 395 isadjacent the forward end 392. There is a coolant port 397 in the seatingportion of the head 395. FIG. 31A shows the coolant delivery passage 398that enters from the rearward end of the holder body and extends allalong the length thereof. FIG. 31B is an isometric view of a holder 390Alike that of FIG. 31, but with the internal coolant passage 398Aentering through the bottom of the holder. FIG. 31C is an isometric viewof a holder 390B like that of FIG. 31, but with the internal coolantpassage 398B entering through the bottom surface of the holder. There isan appreciation that the coolant delivery passage can enter into theholder in any one of a number locations, e.g., rear, side and bottom.

It is apparent that the present invention provides a cutting assembly,as well as a cutting insert assembly, to facilitate enhanced delivery ofcoolant adjacent the interface between the cutting insert and theworkpiece (i.e., the insert-chip interface). By doing so, there is adiminishment of excessive heat at the insert-chip interface in thechipforming removal of material from a workpiece. By providing coolantflow, there is a reduction in excessive heat at the insert-chipinterface to eliminate or reduce build up of chip material. By providingthe flow of coolant to the insert-chip interface, the evacuation ofchips from the insert-chip interface will be facilitated therebyminimizing the potential that a chip will be re-cut. It is apparent thepresent provides advantages connected with decreasing the heat at theinsert-chip interface

The patents and other documents identified herein are herebyincorporated by reference herein. Other embodiments of the inventionwill be apparent to those skilled in the art from a consideration of thespecification or a practice of the invention disclosed herein. It isintended that the specification and examples are illustrative only andare not intended to be limiting on the scope of the invention. The truescope and spirit of the invention is indicated by the following claims.

What is claimed is:
 1. A roughing cutting insert for use in achipforming material removal operation, the cutting insert comprising: acutting insert body having a seating surface and a flank face, a cornercutting region at the intersection of a peripheral edge and the flankadjacent a corresponding corner thereof; the cutting insert bodycontaining a central aperture; the seating surface containing a coolantdelivery trough, the coolant delivery trough having a radial orientationtoward the corresponding corner cutting region, the coolant deliverytrough having a radial outward end terminating at the peripheral edgeand a radial inward end opening into the central aperture; and a pair oflateral topographic regions wherein the one lateral topographic regionis along one side of the coolant delivery trough and the other lateraltopographic region is along other side of the coolant delivery trough,and each one of the topographical regions comprising a peripheral notchterminating at an intersection with the coolant delivery trough near theradial outward end thereof.
 2. The roughing cutting insert according toclaim 1 wherein the peripheral edge having a rake angle equal to betweenabout 0 degrees and +5 degrees.
 3. The roughing cutting insert accordingto claim 1 wherein the cutting insert body having an opposite seatingsurface, and the central aperture extending between the seatingsurfaces, the central aperture having a mediate cylindrical section anda frusto-conical mouth adjacent each of the rake surfaces.
 4. Thecutting insert according to claim 3 wherein the frusto-conical mouthhaving an included angle equal to about 84 degrees and the mediatecylindrical section having a diameter equal to about 7.68 millimeters.5. A roughing cutting insert for use in a chipforming material removaloperation, the cutting insert comprising: a cutting insert body having aseating surface and a flank face, a corner cutting region at theintersection of a peripheral edge region and the flank adjacent acorresponding corner thereof; a pair of lateral peripheral edge regionsextending away from a central peripheral edge region; the cutting insertbody containing a central aperture; the seating surface containing acoolant delivery trough, the coolant delivery trough having a radialorientation toward the corner cutting region, the coolant deliverytrough having a radial outward end terminating at the central peripheraledge region and a radial inward end opening into the central aperture;and a pair of lateral topographic regions wherein the one lateraltopographic region is along one side of the coolant delivery trough andthe other lateral topographic region is along other side of the coolantdelivery trough, and each one of the topographical regions comprising anelongate peripheral notch terminating at an intersection with thecoolant delivery trough near the radial outward end thereof.
 6. Aroughing cutting insert for use in a chipforming material removaloperation, the cutting insert comprising: a cutting insert body having aseating surface and a flank face, a corner cutting region at theintersection of a peripheral edge region and the flank adjacent acorresponding corner thereof; a pair of lateral peripheral edge regionsextending away from central peripheral edge region; the cutting insertbody containing a central aperture; the seating surface containing acoolant delivery trough, the coolant delivery trough having a radialorientation toward the corner cutting region, the coolant deliverytrough having a radial outward end terminating at the central peripheraledge region and a radial inward end opening into the central aperture;and a pair of lateral topographic regions wherein the one lateraltopographic region is along one side of the coolant delivery trough andthe other lateral topographic region is along other side of the coolantdelivery trough, and each one of the topographical regions comprising anelongate peripheral notch terminating at an intersection with thecoolant delivery trough near the radial outward end thereof.